Ford Kuga

 Service Manual

Automatic Transmission/Transaxle » Transmission Description (System Operation and Component Description)
Power flow through the transmission

Clutches and brakes

Item	Description
1	5th gear and reverse gear clutch (C2)
2	1st - 5th gear clutch (C1)
3	Reverse gear brake (B3)
4	1st gear one-way clutch (F2)
5	2nd - 5th gear brake (B2)
6	2nd - 4th gear brake (B1)
7	2nd - 4th gear one-way clutch (F1)
8	Parking lock
9	4th and 5th gear clutch (C3)
10	3rd gear brake (B4) (band brake)
11	1st and 2nd gear and reverse gear brake (B5)
12	Output shaft - transaxle
13	Input shaft - transaxle

The transaxle features three clutches, five brakes, and two one-way clutches.

The clutches are designed as multi-plate clutches.

There are four multi-plate brakes (B1, B2, B3, B5) and one band brake (B4).

Tasks of clutches and brakes

• 1st-5th gear clutch (C1): Connects the input side with the ring gear.
• 5th gear and reverse clutch (C2): Connects the input side with the sun gear.
• 4th and 5th gear clutch (C3): Connects the sun gear with the front planetary gear carriers on the output side.
• 2nd-4th gear brake (B1): Locks the sun gear on the input side.
• 2nd-5th gear brake (B2): Locks the rotational movement of the sun gear on the input side in a counterclockwise direction.
• Reverse gear brake (B3) and 1st gear brake in select-shift mode: Locks the ring gear on the input side.
• 3rd gear brake (B4) (band brake): Locks the two sun gears on the output side.
• 1st and 2nd gear and reverse gear brake (B5): Locks the rear planetary gear carriers on the output side.
• 2nd-4th one-way clutch (F1): Locks the rotational movement of the sun gear on the input side in a counterclockwise direction, if 2nd-5th gear brake (B2) is applied.
• 1st gear one-way clutch (F2): Locks the rotational movement of the ring gear on the input side in a counterclockwise direction.

Function of the clutches and brakes in the gears and when shifting gears in automatic mode and select-shift mode (manual shifting)

Position P (park)

Item	Description
1	1st and 2nd gear and reverse gear brake (B5)
2	Parking lock

The transmission input shaft rotates in the clockwise direction. All clutches and brakes are deactivated and no force is transferred to the planetary gear sets.

No force is transferred to the output shaft. The brake B5 (1) locks the rear planetary gear carrier on the output side. The parking lock (2) engages in the output shaft and stops the vehicle rolling away.

Position P (park)

Item	Description
1	Parking lock
2	1st and 2nd gear and reverse gear brake (B5)

The transmission input shaft rotates in the clockwise direction. All clutches and brakes on the input side are deactivated and no power is transmitted to the planetary gear sets.

No force is transferred to the output shaft. The brake B5 (2) locks the rear planetary gear carrier on the output side. The parking lock (1) is not activated. Since the transaxle input shaft is not positively connected with the input side, the vehicle will start to roll away if it is on an incline.

The brake B5 is activated both in 'P' and in 'N' position to reduce the cut-in pressure that otherwise occurs if several brakes and clutches are activated simultaneously when the selector lever is moved to 'D' or 'R' position. Since the brake B5 is activated both in first and second as well as in reverse gear, this method reduces the total number of transient effects.

Position N (neutral)

Input shaft:

The transmission input shaft rotates in the clockwise direction. Clutch C1 (1) joins the transaxle input shaft with the ring gear, which rotates in clockwise direction. The rear planetary gear set rotates in the clockwise direction. The front larger planetary gear set rotates clockwise with the rear planetary gear set as a single unit.

The front smaller planetary gear set rotates in the clockwise direction. The front annular gear rotates counterclockwise. One-way clutch F2 (2) blocks the front annular gear clockwise rotation.

The front and rear planetary gear carriers are turned clockwise because of the reactive forces from the small gear. The primary idler gear rotates clockwise with the front and rear planetary gear carriers as one unit.

Output shaft:

The secondary idler gear rotates counterclockwise.

The front annular gear rotates counterclockwise with the secondary idler gear as a single unit.

The front planetary gear set rotates in the clockwise direction. The sun gear rotates clockwise.

The rear planetary gear set rotates counterclockwise. Brake B5 (3) prevents rotation of the rear planetary gear carrier. The rear annular gear rotates counterclockwise. The front planetary gear carrier and the final drive pinion rotate counterclockwise with the rear annular gear as one unit. The final drive rotates in the clockwise direction.

Engine braking:

The 1st gear has no engine braking function because the power flow is interrupted by the one-way clutch F2 rotating against the locking direction.

The brake B3 is additionally activated in select-shift mode to guarantee engine braking.

Position D, 2st gear

Input shaft:

The transmission input shaft rotates in the clockwise direction. The clutch C1 (1) joins the transaxle input shaft and the ring gear. The ring gear rotates in clockwise direction. The planetary gear set rotates in clockwise direction.

The front larger planet gear rotates clockwise with the rear planet gear as a single unit. Brakes B2 (2), brake B1 (3) and the one-way clutch F1 (4) prevent rotation of the sun gear.

The front and rear planetary gear carriers are turned clockwise by the front larger gear. The primary idler gear rotates clockwise with the front and rear planetary gear carriers as one unit.

Output shaft:

The secondary idler gear rotates counterclockwise.

The front annular gear rotates counterclockwise with the secondary idler gear as a single unit. The front planetary gear set rotates in the clockwise direction.

The sun gear rotates clockwise. The rear planetary gear set rotates counterclockwise. Brake B5 (5) prevents rotation of the rear planetary gear carrier.

The rear annular gear rotates counterclockwise.

The front planetary gear carrier and the shaft drive pinion rotate in counterclockwise direction with the rear ring gear as one unit. The final drive rotates in the clockwise direction.

Engine braking:

The power is transferred directly to the transmission input shaft without one-way clutch involvement. Engine braking is thus applied.

Position D, 3rd gear

Input shaft:

The transmission input shaft rotates in the clockwise direction. The clutch C1 (5) joins the transaxle input shaft and the ring gear. The ring gear rotates in clockwise direction. The rear planetary gear set rotates in the clockwise direction.

The front larger planet gear rotates clockwise with the rear planet gear as a single unit. Brakes B2 (1) and B1 (2) and also the one-way clutch F1 (3) prevent rotation of the sun gear.

The front and rear planetary gear carriers are turned clockwise because of the reactive forces from the front larger gear. The primary idler gear rotates clockwise with the front and rear planetary gear carriers as one unit.

Output shaft:

The secondary idler gear rotates counterclockwise.

The front annular gear rotates counterclockwise with the secondary idler gear as a single unit. The front planetary gear set rotates in counterclockwise direction. The brake band B4 (4) locks the rotational movement of the sun gear.

The front planetary gear carrier rotates in counterclockwise direction. The front planetary gear carrier and the shaft drive pinion rotate in counterclockwise direction with the rear ring gear as one unit. The final drive rotates in the clockwise direction.

Engine braking:

The power is transferred directly to the transmission input shaft without one-way clutch involvement. Engine braking is thus applied.

Position D, 4th gear

Input shaft:

The transmission input shaft rotates in the clockwise direction. The clutch C1 (5) joins the transaxle input shaft and the ring gear. The ring gear rotates in clockwise direction. The rear planetary gear set rotates in the clockwise direction.

The front larger planet gear rotates clockwise with the rear planet gear as a single unit. Brake B2 (1), one-way clutch F1 (3) and brake B1 (2) prevent rotation of the sun gear.

The front and rear planetary gear carriers are turned clockwise because of the reactive forces from the front larger gear. The primary idler gear rotates clockwise with the front and rear planetary gear carriers as one unit.

Output shaft:

The secondary idler gear rotates clockwise. The front annular gear rotates counterclockwise with the secondary idler gear as a single unit. Clutch C3 (4) connects the sun gear with the front planetary gear carrier.

The front planetary gear set cannot rotate and the output shaft rotates counterclockwise as a single unit. The final drive rotates counterclockwise with the output shaft as a single unit. The final drive rotates in the clockwise direction.

Engine braking:

The power is transferred directly to the transmission input shaft without one-way clutch involvement. Engine braking is thus applied.

Position D, 5th gear

Input shaft:

The transmission input shaft rotates in the clockwise direction. The clutch C1 (2) joins the transaxle input shaft and the ring gear. Clutch C2 (1) connects the transmission input shaft with the sun gear.

The brake B2 (3) locks the rotational movement of the sun gear in a counterclockwise direction.

The rear planetary gear set cannot rotate and the rear planet gear unit rotates clockwise as a single unit. The front planetary gear set cannot rotate with the rear planetary gear set as a single unit. The front planetary gear unit rotates clockwise as one unit. The primary idler gear rotates clockwise with the front planetary gear unit as a single unit.

Output shaft:

The secondary idler gear rotates counterclockwise.

The front annular gear rotates counterclockwise with the secondary idler gear as a single unit.

Clutch C3 (4) connects the sun gear with the front planetary gear carrier.

The front planetary gear set cannot rotate and the output shaft rotates counterclockwise as a single unit. The final drive rotates counterclockwise with the output shaft as a single unit. The final drive rotates in the clockwise direction.

Engine braking:

The power is transferred directly to the transmission input shaft without one-way clutch involvement. Engine braking is thus applied.

Position R (reverse)

Input shaft:

The transmission input shaft rotates clockwise.

Clutch C2 (1) connects the transmission input shaft with the sun gear. The sun gear rotates clockwise.

The rear planetary gear set rotates counterclockwise. The front larger planetary gear set rotates counterclockwise with the rear planetary gear set as a single unit. The front smaller planetary gear set rotates clockwise.

Brake B3 (2) blocks the ring gear in counterclockwise direction. The front and rear planetary gear carriers are turned clockwise by the front smaller gear. The primary idler gear rotates counterclockwise with the front and rear planetary gear carriers as one unit.

Output shaft:

The secondary idler gear rotates clockwise. The front annular gear rotates clockwise with the secondary idler gear as a single unit. The front planetary gear set rotates clockwise. The sun gear rotates in counterclockwise direction.

Brake B5 (3) prevents rotation of the rear planetary gear carrier. The rear annular gear rotates clockwise. The front planetary gear carrier and the final drive pinion rotate clockwise with the rear annular gear as one unit. The final drive rotates counterclockwise.

Engine braking:

The power is transferred directly to the transmission input shaft without one-way clutch involvement. Engine braking is thus applied.

NOTE: The clutch C2 and the brake B3 are only activated at a speed below 7 km/h (approx. 4.35 mph) when shifting from a forward gear to the reverse gear.

System Operation

Gearshift control

Power flow through the transmission

Service instructions

Component Description